Front-To-Front Low Position Tray

ABSTRACT

A tray having a first clearance height when stacked in a front-to-front orientation with a like tray and a second clearance height when stacked in a back-to-front orientation with the like tray is provided. The first clearance height is lower than the second clearance height.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Application No. 61/723,115 filed Nov. 6, 2012, the contents of which are incorporated herein by reference.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

FIELD OF THE INVENTION

The present invention generally relates to a tray that is stackable on a like tray in a front-to-front orientation having a first low clearance height and a back-to-front orientation having a second high clearance height greater than the first clearance height, wherein the tray can be used on standard automation equipment with the first lower clearance height in the front-to-front orientation.

BACKGROUND OF THE INVENTION

Certain trays (sometimes referred to as containers or baskets), such as plastic, molded bakery trays, have always stacked in a certain way to harmonize with automatic filling equipment. Such trays typically have two stacking positions, each having a different clearance height—a low product clearance level in a first stacking position and a high product clearance level in a second stacking position. Historically, such trays had a higher product clearance level when the trays were stacked with all the fronts aligned. That is, an upper tray would stack on a lower tray in a front-to-front orientation. The back-to-front orientation (every other tray in a stack of trays being rotated 180°) was historically a low product clearance level.

The present invention provides a tray that can work with existing automatic equipment to provide a low product clearance level without requiring rotation of alternating trays and a method of stacking such trays.

SUMMARY OF THE INVENTION

The present invention provides a tray, such as a bakery tray, that has a first clearance height when stacked in a front-to-front orientation with a like tray and a second clearance height when stacked in a back-to-front orientation with the like tray. Unlike prior trays, the first clearance height (i.e., the front-to-front orientation) is lower than the second clearance height (i.e., the back-to-back orientation). The tray is designed for use with automated equipment used with such prior trays.

In accordance with an embodiment of the invention, a front-to-front low PCH plastic bakery tray is provided. The bakery tray has a first clearance height when stacked in a front-to-front orientation with a like tray and a second clearance height when stacked in a back-to-front orientation with the like tray. The first clearance height is lower than the second clearance height.

The tray comprises a generally square or rectangular base having a front side, a back side opposite the front side, a first end and a second end opposite the first end. A centrally positioned front wall extends upward from the front side of the base and a centrally positioned back wall extends upward from the back side of the base. A first end wall extends upward from the first end and a second end wall extends upward from the second end of the tray. The front wall extends a first height above the base and the back wall extends a second height above the base greater than the first height. However, in an alternative embodiment the front wall and back wall can be the same height. The first end wall and the second end wall extend upward a third height above the base greater than the second height.

The tray can further comprise a first front transition portion connecting the front wall to the first end wall and a second front transition portion connecting the front wall to the second end wall. The first and second front transition portions extend upward to the third height. Each of the first and second front transition portions can include a horizontal top edge and an angled edge between the top edge and the front wall.

The tray can also include a first back transition portion connecting the back wall to the first end wall and a second back transition portion connecting the back wall to the second end wall. The first and second back transition portions extend upward to the third height. Each of the first and second back transition portions can include a horizontal top edge and an angled edge between the top edge and the back wall.

In accordance with another embodiment of the present invention, a bakery tray having a first stacking position on a like tray, and a second stacking position on the like tray is provided. The tray comprises a generally rectangular base having a front side, a back side opposite the front side, a first end wall and a second end wall. A front wall having a central portion extends upward from the front side of the base a first distance, and a back wall having a central portion extends upward from the back side of the base a second distance. The second distance is greater than the first distance. A first end wall extends upward from the first end of the base, and a second end wall extending upward from the second end of the base. The tray is configured to stack in a front-to-front stacking relationship with a like tray, the front-to-front stacking relationship having a first product clearance height, and a back-to-front stacking relationship with a like tray, the back-to-front stacking relationship having a second product clearance height. The second product clearance height being greater than the first product clearance height.

The bakery tray can be a molded plastic. The tray can be configured to be used with automated equipment.

The first end wall and the second end wall can extend upward from the base a third distance. The third distance is greater than the second distance.

Further aspects of the invention are disclosed in the Figures, and are described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a first upper container stacked on a second lower container with a partial cut-away in a front-to-front low product clear height configuration in accordance with the present invention;

FIG. 2 is a perspective view of a first upper container stacked 180° with respect to a lower container with a partial cut-away in a back-to-front high product clear height configuration in accordance with the present invention;

FIG. 3 is a perspective view of a known first upper container on a second lower container with a partial cut-away in a front-to-front high product clear height configuration; and,

FIG. 4 is a perspective view of a known first upper container stacked 180° with respect to a lower container with a partial cut-away in a back-to-front low product clear height configuration.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there is shown in the Figures, and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

FIG. 1 shows an upper container or tray 10 made in accordance with the present invention stacked on a lower container 10′ in a front-to-front stacking relationship. A right corner portion is cut-away in this Figure for purposes of illustration. Each tray 10, 10′ includes a rectangular base portion 12 having a front wall 14 extending upward from a front side of the base portion 12, a back wall 16 extending upward from a back side of the base portion 12, a first end wall 18 extending upward from a first end of the base portion 12, and a second end wall 20 extending upward from a second end of the base portion 12. In some embodiments one of the front side/back side and the first end/second end can be longer than the other. Alternatively, the base can be square and each side/end can be the same length.

The front wall 14 of each container includes a first central portion 15 that extends upward a first distance from the base portion 12 to a top edge 17. A first transition wall portion 22 connects the central portion 15 of the front wall 14 to the first end wall 18 and a second transition wall portion 23 (not shown in FIG. 1 because of the cut-away—however, the second transition wall portion being a mirror image of the first transition wall portion 22—see FIG. 2) connects the central portion 15 of the front wall to the second end wall 20. The central portion 15 of the front wall 14 is typically very low, and with the transition wall portions 22, 23 forms a Window—sometimes referred to in the industry as a merchandiser window.

Each of the transition wall portions 22, 23 for the front wall 14 includes a horizontal top edge portion 24 flush with an upper edge of the respective end wall, and an angled or inclined portion 26 between the horizontal portion 24 and the central portion 15.

The back wall 16 also includes a central portion 19 that extends upward a second distance to a top edge 21. The second distance is greater than the first distance associated with the top edge 17 of the central portion 15 of the front wall 14. A first transition wall portion 28 connects the central portion 19 of the back wall 16 to the first end wall 18, and a second transition wall portion 30 connects the central portion 19 to the second end wall 20. Each of the transition wall portions 28, 30 of the back wall 16 include a horizontal top edge portion 32 flush the respective end wall 18, 20, and an angled or inclined portion 34 between the horizontal portion 32 to the central portion 19.

Comparing FIGS. 1 and 2, it is evident the product clear height or PCH (i.e., the distance from the upper surface of the base of the lower tray to the lower surface of the base of the upper tray) in the front-to-front configuration (FIG. 1) is lower than the product clear height in the back-to-front configuration (FIG. 2). In this instance, the front-to-front configuration is identified as the “low PCH” and the back-to-front configuration is identified as the “high PCH.”

In contrast to the present invention, prior trays were configured to have a “high PCH” in the front-to-front configuration as shown in FIG. 3, and a “low PCH” in the back-to-front configuration as shown in FIG. 4. In order to obtain a stack of trays having the low PCH, automated equipment had to rotate every other tray in a stack of trays 180° to get a back-to-front- to back-to-front, etc. configuration. The present invention does not require this alternating rotation to achieve the low PCH.

As noted above with respect to the first distance and the second distance, the front side of the tray is typically defined by having a centrally positioned wall extending upward from the base that is much lower than a centrally positioned wall extending upward from the back side of the base. This lower wall can form a merchandiser window that allows one to inspect or remove/place product on the tray when one or more trays are stacked thereon in a particular orientation. Historically, the merchandiser window provided a big space that allowed for visual inspection and removal/placement of product when the trays were stacked in a front-to-front orientation as shown in FIG. 3. In the present invention, the merchandiser window provides a big space when the trays are in a back-to-front orientation as illustrated in FIG. 2.

As used herein, a “like tray” means another tray that is either identical to the tray at issue, or (if not identical) has features to allow for stacking with the tray at issue in a front-to-front stacking relationship and a back-to-front stacking relationship so that the product clearance height in the front-to-front stacking relationship is lower than the clearance height in the back-to-front stacking relationship.

The trays 10 can include feet, runners, receptacles, rails and/or other structure to allow the trays to stack in two or more orientations at different heights (i.e., having different product clear heights). In this regard, the present invention can be implemented in a variety of different styles of bakery trays.

The trays are preferably formed from plastic in an injection molding process. However, the trays can be formed from other materials and/or in other known processes.

Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described. 

I claim:
 1. A bakery tray having a first clearance height when stacked in a front-to-front orientation with a like tray and a second clearance height when stacked in a back-to-front orientation with the like tray, wherein the first clearance height is lower than the second clearance height.
 2. The tray of claim 1 wherein the tray is formed from plastic.
 3. The tray of claim 1 wherein the tray comprises a generally rectangular base having a front side, a back side opposite the front side, a first end and a second end opposite the first end.
 4. The tray of claim 3 further comprising a centrally positioned front wall extending upward from the front side of the base, a centrally positioned back wall extending upward from the back side of the base, a first end wall extending upward from the first end and a second end wall extending upward from the second end of the tray.
 5. The tray of claim 4 wherein the front wall extends a first height above the base and the back wall extends a second height above the base greater than the first height.
 6. The tray of claim 5 wherein the first end wall and the second end wall extend upward a third height above the base greater than the second height.
 7. The tray of claim 6 further comprising a first front transition portion connecting the front wall to the first end wall and a second front transition portion connecting the front wall to the second end wall, the first and second front transition portions extending upward to the third height.
 8. The tray of claim 7 wherein each of the first and second front transition portions include a horizontal top edge and an angled edge between the top edge and the front wall.
 9. The tray of claim 6 further comprising a first back transition portion connecting the back wall to the first end wall and a second back transition portion connecting the back wall to the second end wall, the first and second back transition portions extending upward to the third height.
 10. The tray of claim 9 wherein each of the first and second back transition portions include a horizontal top edge and an angled edge between the top edge and the back wall.
 11. The tray of claim 4 wherein the front side forms a merchandiser window.
 12. A bakery tray having a first stacking position on a like tray, and a second stacking position on the like tray comprising: a generally rectangular base having a front side, a back side opposite the front side, a first end wall and a second end wall; a front wall having a central portion extending upward from the front side of the base a first distance; a back wall having a central portion extending upward from the back side of the base a second distance, the second distance being greater than the first distance; a first end wall extending upward from the first end of the base; a second end wall extending upward from the second end of the base; the tray configured to stack in a front-to-front stacking relationship with a like tray, the front-to-front stacking relationship having a first product clearance height, and a back-to-front stacking relationship with a like tray, the back-to-front stacking relationship having a second product clearance height, the second product clearance height being greater than the first product clearance height.
 13. The bakery tray of claim 12 wherein the tray is plastic.
 14. The bakery tray of claim 12 wherein the tray is configured to be used with automated equipment.
 15. The bakery tray of claim 12 wherein the first end wall and the second end wall extend upward a third distance.
 16. The bakery tray of claim 15 wherein the third distance is greater than the second distance.
 17. The bakery tray of claim 16 wherein the front wall has a first transition portion connecting a first end of the central portion of the front wall to the first end wall, and a second transition portion connecting a second end of the central portion of the front wall to the second end wall.
 18. The bakery tray of claim 17 wherein the first transition portion of the front wall has an upper horizontal surface at the third distance from the base and an inclined surface to the central portion of the front wall.
 19. The bakery tray of claim 18 wherein the back wall has a first transition portion connecting a first end of the central portion of the back wall to the first end wall, and a second transition portion connecting a second end of the central portion of the back wall to the second end wall.
 20. The bakery tray of claim 19 wherein the first transition portion of the back wall has an upper horizontal surface at the third distance from the base and an inclined surface to the central portion of the back wall. 